Organic light emitting display having fourth insulating layer fully covers a contact hole

ABSTRACT

Organic light-emitting display is disclosed. The organic light-emitting display includes a first substrate, a semiconductor layer positioned on the first substrate, a first insulating layer positioned on the semiconductor layer, a gate metal layer positioned on the first insulating layer, a second insulating layer with a contact hole exposing part of the gate metal layer, a source-drain metal layer positioned on the second insulating layer and electrically connected to the gate metal layer via the contact hole, a third insulating layer positioned on the source-drain metal layer, a fourth insulating layer positioned on the third insulating layer, and a pixel electrode positioned on the fourth insulating layer, wherein the fourth insulating layer fully covers the contact hole, and a stepped portion of the pixel electrode caused by the fourth insulating layer is spaced apart from the contact hole.

This application claims the priority benefit of Korean PatentApplication No. 10-2015-0190228 filed on Dec. 30, 2015, which is herebyincorporated herein by reference for all purposes as if fully set forthherein.

BACKGROUND

Field of the Invention

The present disclosure relates to an organic light emitting display.

Discussion of the Related Art

Recently, various flat panel displays that are less bulky and lighterthan cathode ray tubes (CRTs) are being developed. Examples of the flatpanel displays include liquid crystal displays (LCDs), field emissiondisplays (FEDs), plasma display panels (PDPs), organic light-emittingdisplays (OLEDs), etc. Among these types of flat panel displays, theorganic light-emitting displays are self-luminous displays that emitlight through excitation of organic compounds. The organic lightemitting diode displays work without a backlight used in LCDs; thus,they can be lighter and thinner and made in a simplified process. Also,the organic light emitting diode displays can be manufactured at lowtemperatures, have a fast response time of 1 ms or less, and feature lowpower consumption, wide viewing angle, and high contrast.

An organic light-emitting display comprises an emissive layer of organicmaterials between a first electrode as an anode and a second electrodeas a cathode. As such, a hole from the first electrode and an electronfrom the second electrode recombine within the emissive layer, formingan exciton, i.e., a hole-electron pair. Then, energy is created as theexciton returns to the ground state, thereby causing the organiclight-emitting display to emit light. Organic light-emitting displaysmay be classified as bottom-emission devices and top-emission devicesdepending on the direction light exits the device. In the case of thebottom-emission devices, light exits towards the bottom of thesubstrate, that is, from the emissive layer to the first electrode. Inthe case of the top-emission devices, light exits towards the top of thesubstrate, that is, from the emissive layer to the second electrode.

With increasingly higher resolution displays becoming available, theyneed smaller pixel sizes. Thus, the design limit requirements for alayout that requires circuit configuration within a limited space aregetting tighter. In this case, there may be problems (structural weakspots), including the failure to form capacitors and their disappearancedue to a short-circuit between electrodes, which need to be solved.

SUMMARY

Accordingly, the present invention is directed to an organic lightemitting display that substantially obviates one or more of the problemsdue to limitations and disadvantages of the related art

An object of the present disclosure is to provide an organic lightemitting display that solves the problem of failure to form capacitorsand their disappearance due to a short-circuit between electrodes, whichhappens because the design limit requirements for a layout that requirescircuit configuration within a limited space of subpixels are tighter inimplementing a display panel with UHD or higher resolution.

Additional features and advantages of the invention will be set forth inthe description that follows, and in part will be apparent from thedescription, or may be learned by practice of the invention. Theobjectives and other advantages of the invention will be realized andattained by the structure particularly pointed out in the writtendescription and claims hereof as well as the appended drawings.

To achieve these and other advantages and in accordance with the purposeof the present invention, as embodied and broadly described, an organiclight-emitting display comprises a first substrate, a semiconductorlayer positioned on the first substrate, a first insulating layerpositioned on the semiconductor layer, a gate metal layer positioned onthe first insulating layer, a second insulating layer with a contacthole exposing part of the gate metal layer, a source-drain metal layerpositioned on the second insulating layer and electrically connected tothe gate metal layer via the contact hole, a third insulating layerpositioned on the source-drain metal layer, a fourth insulating layerpositioned on the third insulating layer, and a pixel electrodepositioned on the fourth insulating layer, wherein the fourth insulatinglayer fully covers the contact hole, and a stepped portion of the pixelelectrode caused by the fourth insulating layer is spaced apart from thecontact hole.

The fourth insulating layer is a planarization film which is made of anorganic material and makes flat irregularities beneath the fourthinsulating layer.

The second insulating layer has a first stepped portion on the edge ofthe gate metal layer, and the fourth insulating layer covers the steppedportion of the second insulating layer.

The source-drain metal layer has a second stepped portion along thefirst stepped portion of the second insulating layer, and the fourthinsulating layer covers the second stepped portion of the source-drainmetal layer.

The third insulating layer has a third stepped portion along the secondstepped portion of the source-drain metal layer, and the fourthinsulating layer covers the third stepped portion of the thirdinsulating layer.

The first stepped portion, the second stepped portion, and the thirdstepped portion are disposed adjacent to each other.

The gate metal layer in the shape of an island.

The fourth insulating layer is shaped in such a manner as to enclose thesurrounding area of the contact hole.

The fourth insulating layer has a shape in which a part protrudes froman area adjacent to the contact hole.

The gate metal layer comprises a horizontal portion and a verticalportion, and the horizontal portion and the vertical portion areconnected together.

The horizontal portion is parallel to the side surface of the fourthinsulating layer adjacent to the horizontal portion.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate embodiments of the invention andtogether with the description serve to explain the principles of theinvention. In the drawings:

FIG. 1 is a schematic block diagram of an organic light-emitting displayaccording to an exemplary embodiment of the present disclosure;

FIG. 2 is a schematic circuit diagram of a subpixel;

FIG. 3 is a first illustration of the circuit configuration of asubpixel according to an exemplary embodiment of the present disclosure;

FIG. 4 is a second illustration of the circuit configuration of asubpixel according to an exemplary embodiment of the present disclosure;

FIG. 5 is an illustration of a cross-section of a display panelaccording to an exemplary embodiment of the present disclosure;

FIG. 6 is a top plan view showing some subpixels according to anexemplary embodiment of the present disclosure;

FIG. 7 is a cross-sectional view of the area A1-A2 of FIG. 6;

FIG. 8 is a top plan view showing some subpixels according to a testexample of the present disclosure;

FIG. 9 is a cross-sectional view of the area B1-B2 of FIG. 8;

FIG. 10 is an SEM image of the subpixels of the test example;

FIGS. 11 and 12 are a top plan view showing some subpixels according toa first exemplary embodiment of the present disclosure;

FIG. 13 is a cross-sectional view of the area C1-C2 of FIG. 11;

FIG. 14 is a top plan view showing some subpixels according to a secondexemplary embodiment of the present disclosure;

FIG. 15 is a cross-sectional view of the area E1-E2 of FIG. 14; and

FIG. 16 is an SEM image of the subpixels of the second exemplaryembodiment.

DETAILED DESCRIPTION

Hereinafter, exemplary embodiments of the present disclosure will bedescribed in detail with reference to the accompanying drawings. Likereference numerals designate substantially like elements throughout thespecification. In the following description, detailed descriptions ofwell-known functions or configurations associated with the presentdisclosure will be omitted if they are deemed to unnecessarily obscurethe subject matters of the present disclosure. The names of the elementsused in the following description may be selected for ease of writingthe specification, and may be different from the names of parts inactual products.

While a display device according to the present disclosure may be anorganic light-emitting display, a liquid crystal display, anelectrophoresis display, etc., the present disclosure will be describedwith respect to an organic light-emitting display. The organiclight-emitting display comprises an emissive layer of organic materialsbetween a first electrode as an anode and a second electrode as acathode. As such, a hole from the first electrode and an electron fromthe second electrode recombine within the emissive layer, forming anexciton, i.e., a hole-electron pair. Then, energy is created as theexciton returns to the ground state, thereby causing the self-luminousdisplay to emit light. The organic light-emitting display according tothe present disclosure may be a plastic display with display elementsthat are formed on a flexible plastic substrate, as well as on a glasssubstrate.

FIG. 1 is a schematic block diagram of an organic light-emitting displayaccording to an exemplary embodiment of the present disclosure. FIG. 2is a schematic circuit diagram of a subpixel. FIG. 3 is a firstillustration of the circuit configuration of a subpixel according to anexemplary embodiment of the present disclosure. FIG. 4 is a secondillustration of the circuit configuration of a subpixel according to anexemplary embodiment of the present disclosure. FIG. 5 is anillustration of a cross-section of a display panel according to anexemplary embodiment of the present disclosure.

As shown in FIG. 1, an organic light-emitting display according to anexemplary embodiment of the present disclosure comprises an imageprocessor 110, a timing controller 120, a data driver 130, a scan driver140, and a display panel 150.

The image processor 110 outputs a data enable signal DE, etc., alongwith an externally supplied data signal DATA. The image processor 110may output one or more among a vertical synchronization signal,horizontal synchronization signal, and clock signal, in addition to thedata enable signal DE, but these signals are not shown in the drawingsfor convenience of explanation.

The timing controller 120 receives the data signal DATA from the imageprocessor 110, along with the data enable signal DE or driving signalsincluding the vertical synchronization signal, horizontalsynchronization signal, and clock signal. Based on the driving signals,the timing controller 120 outputs a gate timing control signal GDC forcontrolling the operation timing of the scan driver 140 and a timingcontrol signal DDC for controlling the operation timing of the datadriver 130.

In response to the data timing control signal DDC supplied from thetiming controller 120, the data driver 130 samples and latches the datasignal DATA supplied form the timing controller 120, converts it to agamma reference voltage, and outputs the gamma reference voltage. Thedata driver 130 outputs the data signal through data lines DL1 to DLn.The data driver 130 may come in the form of an IC.

In response to the gate timing control signal GDC supplied from thetiming controller 120, the scan driver 140 outputs a scan signal whileshifting the level of a gate voltage. The scan driver 140 outputs thescan signal through scan lines GL1 to GLm. The scan driver 140 comes inthe form of an IC, or is formed on the display panel 150 by thegate-in-panel technology.

The display panel 150 displays an image, corresponding to the datasignal DATA and scan signal respectively supplied from the data driver130 and scan driver 140. The display panel 150 comprises subpixels SPthat operate to display an image.

The subpixels are made to be top-emitting, bottom-emitting, ordual-emitting depending on the structure. The subpixels SP comprise redsubpixels, green subpixels, and blue subpixels, or comprise whitesubpixels, red subpixels, green subpixels, and blue subpixels. Thelight-emission area of one or more of the subpixels SP is different fromthat of the others depending on the light-emission characteristics.

As shown in FIG. 2, a subpixel comprises a switching transistor SW, adriving transistor DR, a capacitor Cst, a compensation circuit CC, andan organic light-emitting diode OLED.

In response to a scan signal supplied through the first scan line GL1,the switching transistor SW is switched on so that a data signalsupplied through the first data line DL1 is stored as a data voltage ina capacitor Cst. The driving transistor DR operates so that a drivingcurrent flows between a first power supply line EVDD and a second powersupply line EVSS in response to the data voltage stored in the capacitorCst. The organic light-emitting diode OLED operates to emit light inresponse to the drive current formed by the driving transistor DR.

The compensation circuit CC is a circuit added to the subpixel tocompensate the threshold voltage, etc. of the driving transistor DR. Thecompensation circuit CC consists of one or more transistors. Thecompensation circuit CC has a wide variety of configurations dependingon the compensation method, so an example of this will be describedbelow.

As shown in FIGS. 3 and 4, the compensation circuit CC comprises asensing transistor ST and a sensing line VREF. The sensing transistor STis connected between a source line of the driving transistor DR and theanode (hereinafter, sensing node) of the organic light-emitting diodeOLED. The sensing transistor ST operates to supply a reset voltage (orsensing voltage) passed through the sensing line VREF to the sensingnode or to sense the voltage or current at the sensing node.

The switching transistor SW has a first electrode connected to the firstdata line DL1 and a second electrode connected to a gate electrode ofthe driving transistor DR. The driving transistor DR has a firstelectrode connected to the first power supply line EVDD and a secondelectrode connected to the anode of the organic light-emitting diodeOLED. The capacitor Cst has a first electrode connected to the gateelectrode of the driving transistor DR and a second electrode connectedto the anode of the organic light-emitting diode. The organiclight-emitting diode OLED has the anode connected to the secondelectrode and a cathode connected to the second power supply line EVSS.The sensing transistor ST has a first electrode connected to the sensingline VREF and a second electrode connected to the anode, which is asensing node, of the organic light-emitting diode OLED.

The operating time of the sensing transistor ST may be similar to or thesame as or different from that of the switching transistor SW dependingon the compensation algorithm (or the configuration of the compensationcircuit).

In an example, the switching transistor SW may have a gate electrodeconnected to a 1a-th scan line GL1 a, and the sensing transistor ST mayhave a gate electrode connected to a 1b-th scan line GL1 b. In anotherexample, the 1a-th scan line GL1 a connected to the gate electrode ofthe switching transistor SW and the 1b-th scan line GL1 b connected tothe gate electrode of the sensing transistor ST may be connected so thatthey can be commonly shared.

The sensing line VREF may be connected to the data driver. In this case,the data driver may sense the sensing node of the subpixel and perform acompensation according to the sensing result, in real time during anon-display period of an image or an N frame period (N is an integerequal to or greater than 1). Meanwhile, the switching transistor SW andthe sensing transistor ST may be turned on at the same time. In thiscase, a sensing operation through the sensing line VREF and a dataoutput operation for outputting a data signal are distinguished based onthe time-division method of the data driver.

Besides, a digital data signal, an analog data signal, or a gammavoltage may be compensated according to a sensing result. Also, acompensation circuit that generates a compensation signal (orcompensation voltage) based on the sensing result may be implementedwithin the data driver, within the timing controller, or as a separatecircuit.

FIGS. 3 and 4 illustrate, by way of example, a subpixel with athree-capacitor one-capacitor 3T1C structure which comprises a switchingtransistor SW, a driving transistor DR, a capacitor Cst, an organiclight-emitting diode OLED, and a sensing transistor. Besides, thesubpixel may consist of 3T2C, 4T2C, 5T1C, 6T2C, etc., with the additionof a compensation circuit CC.

Meanwhile, the configuration of a light shielding layer is differentbetween the circuit of the subpixel of FIG. 3 and the circuit of thesubpixel of FIG. 4. The light shielding layer LS exists to shieldoutside light. If the light shielding layer LS is made of a metallicmaterial, the problem that the parasitic voltage is charged is induced.For this reason, the light shielding layer LS is connected to the sourceelectrode of the driving transistor DR.

Specifically, the light shielding layer LS may be disposed in the lowerpart of a channel region of the driving transistor DR, as shown in FIG.3, or the light shielding layer LS may be disposed in the lower parts ofchannel regions of the switching transistor SW and sensing transistorST, as well as in the lower part of the channel region of the drivingtransistor DR, as shown in FIG. 4.

The light shielding layer LS may be used only for blocking outside light(FIG. 3), or the light shielding layer LS may be used as an electrodethat facilitates connections with other electrodes or lines andconstitutes a capacitor, etc.

As shown in FIG. 5, subpixels are formed on a display area AA of a firstsubstrate 150 a, based on the circuit explained with respect to FIG. 3or FIG. 4. The subpixels formed on the display area AA are sealed with aprotective film (or protective substrate) 150 b. Unexplained referencenumeral NA refers to a non-display area.

The subpixels are horizontally or vertically placed in the order of red(R), white (W), blue (B), and green (G). A red (R) subpixel, a white (W)subpixel, a blue (B) subpixel, and a green (G) subpixel constitute apixel P. The order of placement of the subpixels may vary depending onthe light-emitting material, light-emission area, the configuration (orstructure) of the compensation circuit, etc. Also, a red (R) subpixel, ablue (B) subpixel, and a green (G) subpixel may constitute a pixel P.

FIG. 6 is a top plan view showing some subpixels according to anexemplary embodiment of the present disclosure. FIG. 7 is across-sectional view of the area A1-A2 of FIG. 6.

As shown in FIGS. 6 and 7, horizontally placed first to fourth subpixelsSPn1 to SPn4 constitute a pixel. For example, the first subpixel SPn1may be a red subpixel (R), the second subpixel SPn2 may be a whitesubpixel (W), the third subpixel SPn3 may be a blue subpixel (B), andthe fourth subpixel SPn4 may be a green subpixel (G).

A first power supply line EVDD is vertically placed on the left side ofthe first subpixel SPn1. The first power supply line EVDD is connectedcommonly to the first subpixel SPn1 and the second subpixel SPn2. Afirst data line DLn1 and a second data line DLn2 are vertically placedin the space WA between the first subpixel SPn1 and the second subpixelSPn2. The first data line DLn1 is connected to the first subpixel SPn1,and the second data line DLn2 is connected to the second subpixel SPn2.“WA” is defined as a wiring area.

A sensing line VREF is vertically placed on the left side of the thirdsubpixel SPn3. The sensing line VREF is connected commonly to the firstto fourth subpixels SPn1 to SPn4. A third data line DLn3 and a fourthdata line DLn4 are vertically placed in the space WA between the thirdsubpixel SPn3 and the fourth subpixel SPn4. The third data line DLn3 isconnected to the third subpixel SPn3, and the fourth data line DLn4 isconnected to the fourth subpixel SPn4.

A scan line GL1 a is horizontally placed in the areas of the sensingtransistors ST included in the first to fourth subpixels SPn1 to SPn4.The scan line GL1 is connected to the gate electrodes of the sensingtransistor ST and switching transistor SW. The sensing line VREFcomprises a vertical sensing line VREFM vertically placed and ahorizontal sensing line VREFS horizontally placed. The sensingtransistors ST of the first to fourth subpixels SPn1 to SPn4 areconnected to the vertical sensing line VREFM through the horizontalsensing line VREFS.

A cross-sectional structure of the display panel will be described belowby taking part of the first subpixel SPn1 as an example.

A light shielding layer 151 is formed on the first substrate 150 a. Thelight shielding layer 151 may correspond to the channel region of thedriving transistor DR, or divided into sections corresponding to thechannel regions of the driving transistor DR, sensing transistor ST, andswitching transistor SW, respectively.

A buffer layer 152 and a semiconductor layer 153 are formed on the lightshielding layer 151. The light shielding layer 151, the buffer layer152, and the semiconductor layer 153 may be sequentially laminated onthe first substrate 150 a, and then all of them may be patterned(batch-patterned) in the shape of an island by using the same mask. Thesemiconductor layer 153 illustrated in the figure is a semiconductorlayer for the driving transistor DR, which is composed of an oxidesemiconductor (e.g., IGZO). The parts of the semiconductor layer 153corresponding to source and drain regions, except the part correspondingto a channel region, are made conductive and become metal electrodes orwires (metallization). The conduction process may be performed by, butnot limited to, plasma etching.

A first insulating layer 154 is formed on the semiconductor layer 153,and a gate metal layer 155 is formed on the first insulating layer 154.The first insulating layer 154 may be defined as a gate insulatinglayer, and may be patterned in the shape of an island, like theoverlying gate electrode (or gate metal layer). The first insulatinglayer 154 may be one selected from the group consisting of silicon-basedmaterials: SiO₂, SiNx, and SiON.

The gate metal layer 155 is used as the gate electrode of the drivingtransistor DR of the first subpixel SPn1. Also, the gate metal layer 155is used as an electrode, etc. that electrically connects the first tofourth subpixels SPn1 to SPn4 and the first power supply line EVDD.

A second insulating layer 156 is formed on the gate metal layer 155. Thesecond insulating layer 156 may be defined as an interlayer insulatinglayer that electrically insulates between the underlying structure andthe overlying structure. The second insulating layer 156 may have aplurality of contact holes exposing part of the underlying structure.The contact holes are formed by using a hole mask.

A source-drain metal layer 157 is formed on the second insulating layer156. The source-drain metal layer 157 is split into lines constitutingthe first power supply line EVDD, data lines DLn1 to DLn4, and sensingline VREF, and electrodes constituting the transistors and capacitorsincluded in the subpixels.

Referring to the part of the driving transistor DR corresponding to apart of the source-drain metal layer 157, the part of the source-drainmetal layer 157 is connected to the semiconductor layer 153 s and 153 dof the source and drain regions, which become the source electrode 157 sand drain electrode 157 d of the driving transistor DR. Thesemiconductor layer 153 a of the channel region is protected by thelight shielding layer 151.

A third insulating layer 158 is formed on the source-drain metal layer157. The third insulating layer 158 may be defined as a protective layerfor protecting the structural components such as the transistors, etc.formed on the first substrate 150 a.

A color filter 159 is formed on the third insulating layer 158,corresponding to an opening area. If an organic light-emitting diode tobe formed later emits white light, the color filter 159 is formed on thethird insulating layer 158. On the contrary, if the organiclight-emitting diode emits light of red, green, or blue, the colorfilter 159 is not formed on the third insulating layer 158.

A fourth insulating layer 160 is formed on the third insulating layer158. The fourth insulating layer 160 may be defined as a coating layerfor making flat the surface. The third insulating layer 158 and thefourth insulating layer 160 have a contact hole exposing part of thesource electrode 157 s (or drain electrode; there are two types oftransistors: p-type and n-type, and the source and drain electrodes arereversed depending on the transistor type)

A pixel electrode 161 is formed on the fourth insulating layer 160. Thepixel electrode 161 may be defined as the anode of the organiclight-emitting diode. The pixel electrode 161 is electrically connectedto the source electrode 157 s exposed through the fourth insulatinglayer 160. The pixel electrode 161 may be a transparent electrode so asto give off the light emitted from an organic emissive layer towards thefirst substrate 150 a.

A bank layer 162 is formed on the pixel electrode 161 and the fourthinsulating layer 160. The bank layer 162 has an opening area exposingpart of the pixel electrode 161, and defines an actual emissive area.

An organic emissive layer 163 is formed on the bank layer 162. Theorganic emissive layer 163 is a layer that emits light, which may emitlight of white, red, green, or blue. The organic emissive layer 163 mayfurther comprise a functional layer, such as a hole injection layer,hole transport layer, electron transport layer, or electron injectionlayer, or a compensation layer such as a hole blocking layer orinterface buffer layer, in addition to the emissive layer.

An upper electrode 164 is formed on the organic emissive layer 163. Theupper electrode 164 may be defined as the cathode of the organiclight-emitting diode. The upper electrode 164 is electrically connectedto a second power supply line (not shown). The upper electrode 164 maybe an opaque electrode so as to give off the light emitted from theorganic emissive layer only towards the first substrate 150 a.Alternatively, the upper electrode 164 may be a transparent electrode soas to give off the light emitted from the organic emissive layer in adirection opposite to the first substrate 150, depending on the purpose,function, etc. of the display panel.

A capacitor Cst is formed in each of the first to fourth subpixels SPn1to SPn4. The capacitor Cst may have a monolayer or multilayer structureby using part of the light shielding layer, part of the gate metallayer, part of the semiconductor layer, part of the source-drain metallayer, part of the pixel electrode, and the insulating layers situatedbetween these layers.

For display panels with UHD or higher resolution, the subpixel size issmaller compared to the previous one. Thus, the design limitrequirements for a layout that requires circuit configuration within alimited space are getting tighter. In this case, the insulating layersalong stepped portions caused by the lamination of multiple layersbecome thinner, and this may lead to structural problems (structuralweak spots), including an increased risk of short-circuits betweenelectrode layers.

Now, a test example with the above-mentioned problems will beconsidered, and structures for overcoming these problems according toexemplary embodiments will be described.

FIG. 8 is a top plan view showing some subpixels according to TestExample of the present disclosure. FIG. 9 is a cross-sectional view ofthe area B1-B2 of FIG. 8. FIG. 10 is an SEM image of the subpixels ofthe test example.

Test Example

As shown in FIGS. 8 to 10, in the test example, part of thesemiconductor layer 153M of the driving transistor DR is configured as alower electrode of the capacitor Cst, and part of the source-drain metallayer 157 of the driving transistor DR is configured as an upperelectrode of the capacitor Cst.

Then, the gate electrode of the driving transistor DR and the upperelectrode of the capacitor Cst are electrically connected by using apart of the gate metal layer 155 constituting the gate electrode of thedriving transistor DR. That is, the part of the gate metal layer 155serves as the gate electrode of the driving transistor DR and also as aconnecting electrode that electrically connects the gate electrode ofthe driving transistor DR and the upper electrode of the capacitor Cst.

The source and drain regions—part of the semiconductor layer 153M of thedriving transistor DR—become conductive and therefore correspond to theparts of the semiconductor layer that are turned into conductors, sothey will be hereinafter called conductive regions 153M of thesemiconductor layer.

Next, a fourth insulating layer 160 is formed on the source-drain metallayer 157. The fourth insulating layer 160 is an organic film whichserves as a planarization film for making flat irregularities beneathit. A pixel electrode 161 is formed on the fourth insulating layer 160and the third insulating layer 158.

The structure corresponding to the gate metal layer 155 will bedescribed below with reference to a part of the cross-section accordingto the test example.

The conductive regions 153M of the semiconductor layer are formed on thebuffer layer 152 covering the first substrate 150 a. A first insulatinglayer 154 is formed in the shape of an island on the conductive regions153M of the semiconductor layer. A gate metal layer 155 is formed on thefirst insulating layer 154. A second insulating layer 156 with a contacthole exposing part of the gate metal layer 155 is formed on the gatemetal layer 155. A source-drain metal layer 157 to be electricallyconnected to the gate metal layer 155 via the contact hole is formed onthe second insulating layer 156.

Next, a third insulating layer 158 is formed on the source-drain metallayer 157. A fourth insulating film 160 is formed on the thirdinsulating layer 158. The fourth insulating layer 160 is an organic filmwhich serves as a planarization film for making flat irregularitiesbeneath it. A pixel electrode 161 is formed on the fourth insulatinglayer 160 and the third insulating layer 158.

In the test example, the fourth insulating layer 160 is shaped in such away that it covers only part of the gate metal layer 155 but not theother parts of the gate metal layer 155. That is, the fourth insulatinglayer 160 covers only part of the contact hole CH in the secondinsulating layer 156 formed on the gate metal layer 155.

The fourth insulating layer 160 serves to make flat irregularitiesbeneath it so that the pixel electrode 161 where the organic emissivelayer is formed is made flat. The fourth insulating layer 160 ispositioned under the pixel electrode 161, and corresponds to a part ofthe pixel electrode 161 where the organic emissive layer is formed. Inthe drawing, the area from the gate metal layer 155 to the 1a-th scanline GL1 a is a non-emissive area where the pixel electrode 161 does notneed to be planarized. Thus, the fourth insulating layer 160 of the testexample is shaped in such a manner as to cover only part of the gatemetal layer 155, starting from the upper part in the drawing. That is,the fourth insulating layer 160 cover only part of the gate metal layer155, and the stepped portion of the pixel electrode 161 caused by thefourth insulating layer 160 overlaps the contact hole CH.

The second insulating layer 156 is made thin, in order to improve thedriving capability of top-gate driving transistors and meet the processrequirements for high-resolutions, including forming a first capacitorCst1 between the conductive regions 153M of the semiconductor and thesource-drain metal layer 157. Also, the third insulating layer 158 ismade thin, in order to form a second capacitor Cst2 between thesource-drain metal layer 157 and the pixel electrode 161.

With the above-described conditions, the driving capability of thetop-gate driving transistors or the formation of the first and secondcapacitors Cst1 and Cst2 can be improved. However, the second insulatinglayer 156, source-drain metal layer 157, and third insulating layer 158are made thin along the stepped portion of the gate metal layer 155.

As a consequence, a seam is formed on the second insulating layer 156along the stepped portion of the gate metal layer 155, a seam is formedon the source-drain metal layer 157 formed on the second insulatinglayer 156, a seam is formed on the third insulating layer 158 formed onthe source-drain metal layer 157, and a seam is formed on the pixelelectrode 161 formed on the third insulating layer 158. Due to the seamsformed on the second insulating layer 156, source-drain metal layer 157,and third insulating layer 158, a short-circuit occurs between the pixelelectrode 161 and the source-drain metal layer 157. As a result, thesecond capacitor Cst2 is not formed and disappears.

That is, the above-described conditions can affect the drivingcapability of top-gate driving transistors and lead to structuralproblems (structural weak spots) with the electrode portion forming thefirst and second capacitors Cst1 and Cst2. This may decrease thereliability or production yield of the display panel.

First Exemplary Embodiment

FIGS. 11 and 12 are a top plan view showing some subpixels according toa first exemplary embodiment of the present disclosure. FIG. 13 is across-sectional view of the area C1-C2 of FIG. 11.

As shown in FIGS. 11, 12, and 13, in the first exemplary embodiment,part of the semiconductor layer 153M of the driving transistor DR isconfigured as a lower electrode of the first capacitor Cst1, and part ofthe source-drain metal layer 157 of the driving transistor DR isconfigured as an upper electrode of the first capacitor Cst1. Also, partof the source-drain metal layer 157 is configured as a lower electrodeof the second capacitor Cst2, and part of the pixel electrode 161 isconfigured as an upper electrode of the second capacitor Cst2.

Then, the gate electrode of the driving transistor DR and the upperelectrode of the first capacitor Cst1 are electrically connected byusing a part of the gate metal layer 155 constituting the gate electrodeof the driving transistor DR. That is, the part of the gate metal layer155 serves as the gate electrode of the driving transistor DR and alsoas a connecting electrode that electrically connects the gate electrodeof the driving transistor DR and the upper electrode of the firstcapacitor Cst1. The source and drain regions—part of the semiconductorlayer 153M of the driving transistor DR—become conductive and thereforecorrespond to the parts of the semiconductor layer that are turned intoconductors, so they will be hereinafter called conductive regions 153Mof the semiconductor layer.

Next, a fourth insulating layer 160 is formed on the source-drain metallayer 157. The fourth insulating layer 160 is an organic film whichserves as a planarization film for making flat irregularities beneathit. A pixel electrode 161 is formed on the fourth insulating layer 160and the third insulating layer 158.

The structure corresponding to the gate metal layer 155 will bedescribed below with reference to a part of the cross-section accordingto the test example.

The conductive regions 153M of the semiconductor layer are formed on thebuffer layer 152 covering the first substrate 150 a. A first insulatinglayer 154 is formed in the shape of an island on the conductive regions153M of the semiconductor layer. A gate metal layer 155 is formed on thefirst insulating layer 154. A second insulating layer 156 with a contacthole exposing part of the gate metal layer 155 is formed on the gatemetal layer 155. A source-drain metal layer 157 to be electricallyconnected to the gate metal layer 155 via the contact hole is formed onthe second insulating layer 156.

Next, a third insulating layer 158 is formed on the source-drain metallayer 157. A fourth insulating film 160 is formed on the thirdinsulating layer 158. The fourth insulating layer 160 is an organic filmwhich serves as a planarization film for making flat irregularitiesbeneath it. A pixel electrode 161 is formed on the fourth insulatinglayer 160 and the third insulating layer 158.

In the test example, the fourth insulating layer 160 is shaped in such away that it covers only part of the gate metal layer 155 but not theother parts of the gate metal layer 155.

The fourth insulating layer 160 serves to make flat irregularitiesbeneath it so that the pixel electrode 161 where the organic emissivelayer is formed is made flat. The fourth insulating layer 160 ispositioned under the pixel electrode 161, and corresponds to a part ofthe pixel electrode 161 where the organic emissive layer is formed. Inthe figure, the area from the gate metal layer 155 to the 1a-th scanline GL1 a is a non-emissive area where the pixel electrode 161 does notneed to be planarized. Thus, the fourth insulating layer 160 of the testexample is shaped in such a manner as to cover only part of the gatemetal layer 155, starting from the upper part in the drawing.

The second insulating layer 156 is made thin, in order to improve thedriving capability of top-gate driving transistors and meet the processrequirements for high-resolutions, including forming a first capacitorCst1 between the conductive regions 153M of the semiconductor and thesource-drain metal layer 157. Also, the third insulating layer 158 ismade thin, in order to form a second capacitor Cst2 between thesource-drain metal layer 157 and the pixel electrode 161.

With the above-described conditions, the driving capability of thetop-gate driving transistors or the formation of the first and secondcapacitors Cst1 and Cst2 can be improved. However, the second insulatinglayer 156, source-drain metal layer 157, and third insulating layer 158are made thin along the stepped portion of the gate metal layer 155.

As a consequence, a seam is formed on the second insulating layer 156 onthe stepped portion of the gate metal layer 155, a seam is formed on thesource-drain metal layer 157 formed on the second insulating layer 156,a seam is formed on the third insulating layer 158 formed on thesource-drain metal layer 157, and a seam is formed on the pixelelectrode 161 formed on the third insulating layer 158. Due to the seamsformed on the second insulating layer 156, source-drain metal layer 157,and third insulating layer 158, a short-circuit occurs between the pixelelectrode 161 and the source-drain metal layer 157. As a result, thesecond capacitor Cst2 is not formed and disappears.

However, in the first exemplary embodiment of the present disclosure,the first insulating layer 160 serving as a planarization film is formedin such a manner as to fully overlap the gate metal layer 155, in orderto overcome the problems occurring in the test example. Morespecifically, the fourth insulating layer 160 fully covers the gatemetal layer 155, and the stepped portion of the pixel electrode 161,caused by the fourth insulating layer 160, is spaced apart from thecontact hole CH.

Since the second insulating layer 156 covers the gate metal layer 155,it has a first stepped portion SC1 on the edge of the gate metal layer155. The source-drain metal layer 157 formed on the second insulatinglayer 156 has a second stepped portion SC2 along the first steppedportion SC1 of the second insulating layer 156. The third insulatinglayer 158 formed on the source-drain metal layer 157 has a third steppedportion SC3 along the second stepped portion SC2 of the source-drainmetal layer 157.

The fourth insulating layer 160 of this invention is formed in such amanner as to fully cover the first stepped portion SC1 of the thirdinsulating layer 158, the second stepped portion SC2 of the source-drainmetal layer 157, and the third stepped portion SC3 of the thirdinsulating layer 158, in order to fill in the first stepped portion SC1of the third insulating layer 158, the second stepped portion SC2 of thesource-drain metal layer 157, and the third stepped portion SC3 of thethird insulating layer 158. The first stepped portion SC1 of the thirdinsulating layer 158, the second stepped portion SC2 of the source-drainmetal layer 157, and the third stepped portion SC3 of the thirdinsulating layer 158 are formed near the contact hole CH of the gatemetal layer 155. As such, as shown in FIGS. 11 and 12, the fourthinsulating layer 160 of this invention is shaped in such a manner as tocompletely enclose the surrounding area of the contact hole CH, allowingthe stepped portion of the pixel electrode 161 to be spaced apart fromthe contact hole CH. The fourth insulating layer 160 has a shape inwhich a part protrudes from an area adjacent to the contact hole CH.

Thus, the fourth insulating layer 160 of this invention fully covers andtherefore planarizes the first stepped portion SC1 of the thirdinsulating layer 158, the second stepped portion SC2 of the source-drainmetal layer 157, and the third stepped portion SC3 of the thirdinsulating layer 158, thereby preventing a short-circuit between thepixel electrode 161 formed on the fourth insulating layer 160 and thesource-drain metal layer 157.

Consequently, in the first exemplary embodiment, even if seams areformed on the first stepped portion SC1 of the third insulating layer158, the second stepped portion SC2 of the source-drain metal layer 157,and the third stepped portion SC3 of the third insulating layer 158, noshort-circuit occurs between the pixel electrode 161 and thesource-drain metal layer 157 because the fourth insulating layer 160 isplanarized. This will result in solving the problem that the secondcapacitor Cst2 disappears. That is, with the above-described conditions,the driving capability of top-gate driving transistors can be improved,and the structural problems (structural weak spots) with the electrodeportions can be solved. This eliminates the problem of the decrease inthe reliability or production yield of the display panel.

As can be seen from the comparison between the test example and thefirst exemplary embodiment, the problems in the test example occurfrequently when the second insulating layer 156 and the third insulatinglayer 158 are made thin to improve the driving capability of thetop-gate driving transistors. Thus, in the first exemplary embodimentinvention, problems that may occur between the upper and lowerelectrodes of the second capacitor can be solved by coveringshort-circuit areas with the fourth insulating layer corresponding tothe planarization film. Accordingly, it will be appreciated by a personhaving ordinary skill in the art that the present disclosure isapplicable to capacitors with other layouts.

Second Exemplary Embodiment

FIG. 14 is a top plan view showing some subpixels according to a secondexemplary embodiment of the present disclosure. FIG. 15 is across-sectional view of the area E1-E2 of FIG. 14. FIG. 16 is an SEMimage of the subpixels of the second exemplary embodiment. A redundantexplanation of the foregoing first exemplary embodiment will be omittedbelow.

As shown in FIGS. 14 and 15, in the second exemplary embodiment, part ofthe semiconductor layer 153M of the driving transistor DR is configuredas a lower electrode of the first capacitor Cst1, and part of thesource-drain metal layer 157 of the driving transistor DR is configuredas an upper electrode of the first capacitor Cst1. Also, part of thesource-drain metal layer 157 is configured as a lower electrode of thesecond capacitor Cst2, and part of the pixel electrode 161 is configuredas an upper electrode of the second capacitor Cst2.

In the test example and the first exemplary embodiment, the gate metallayer 155 has an T-shape. Thus, by increasing the area of the fourthinsulating layer 160 and covering the surrounding area of the contacthole CH with the fourth insulating layer 160, a short-circuit betweenthe electrodes of the second capacitor Cst2 is prevented. In the secondexemplary embodiment, unlike the first exemplary embodiment, the gatemetal layer 155 has a shape, other than the T-shape, with a verticalportion and a horizontal portion. Accordingly, a short-circuit betweenthe electrodes of the second capacitor Cst2 is prevented simply bychanging the shape of the gate metal layer 155, without increasing thearea of the fourth insulating layer 160.

More specifically, the gate metal layer 155 comprises a vertical portionVEP and a horizontal portion HOP intersecting the vertical portion VEP.The vertical portion VEP is an area where the contact hole CH connectedto the source-drain metal layer 157 is formed, which is disposedparallel to the data line DLn1. The horizontal portion HOP intersectsthe vertical portion VEP, and is disposed parallel to the gate line GL1a. The horizontal portion HOP is parallel to the side surface of thefourth insulating layer 160 adjacent to the horizontal portion HOP.Accordingly, the present disclosure can prevent a short-circuit betweenthe electrodes of the second capacitor Cst2 simply by forming the gatemetal layer 155 with the horizontal portion VEP and changing the shapeof the gate metal layer 155 so that the fourth insulating layer 160fully overlaps the gate metal layer 155.

The fourth insulating layer 160 is formed on the source-drain metallayer 157. The fourth insulating layer 160 fully overlaps the gate metallayer 155. The fourth insulating layer 160 fully covers the gate metallayer 155, and the stepped portion of the pixel electrode 161, caused bythe fourth insulating layer 160, is spaced apart from the contact holeCH.

Since the second insulating layer 156 covers the gate metal layer 155,it has a first stepped portion SC1 on the edge of the gate metal layer155. The source-drain metal layer 157 formed on the second insulatinglayer 156 has a second stepped portion SC2 along the first steppedportion SC1 of the second insulating layer 156. The third insulatinglayer 158 formed on the source-drain metal layer 157 has a third steppedportion SC3 along the second stepped portion SC2 of the source-drainmetal layer 157. The first stepped portion SC1, the second steppedportion SC2, and the third stepped portion SC3 are disposed adjacent toeach other.

The fourth insulating layer 160 of this invention is formed in such amanner as to fully cover the first stepped portion SC1 of the thirdinsulating layer 158, the second stepped portion SC2 of the source-drainmetal layer 157, and the third stepped portion SC3 of the thirdinsulating layer 158, in order to fill in the first stepped portion SC1of the third insulating layer 158, the second stepped portion SC2 of thesource-drain metal layer 157, and the third stepped portion SC3 of thethird insulating layer 158. The first stepped portion SC1 of the thirdinsulating layer 158, the second stepped portion SC2 of the source-drainmetal layer 157, and the third stepped portion SC3 of the thirdinsulating layer 158 are formed near the contact hole CH of the gatemetal layer 155. As such, as shown in FIGS. 14 and 15, the fourthinsulating layer 160 of this invention is shaped in such a manner as tofully cover the gate metal layer 155 and allow the stepped portion ofthe pixel electrode 161 and the contact hole CH to be spaced apart fromeach other.

Thus, as shown in FIG. 16, the fourth insulating layer 160 of thisinvention fully covers and therefore planarizes the first steppedportion SC1 of the third insulating layer 158, the second steppedportion SC2 of the source-drain metal layer 157, and the third steppedportion SC3 of the third insulating layer 158, thereby preventing ashort-circuit between the pixel electrode 161 formed on the fourthinsulating layer 160 and the source-drain metal layer 157.

Consequently, in the second exemplary embodiment, even if seams areformed on the first stepped portion SC1 of the third insulating layer158, the second stepped portion SC2 of the source-drain metal layer 157,and the third stepped portion SC3 of the third insulating layer 158, noshort-circuit occurs between the pixel electrode 161 and thesource-drain metal layer 157 because the fourth insulating layer 160 isplanarized. This will result in solving the problem that the secondcapacitor Cst2 disappears. That is, with the above-described conditions,the driving capability of top-gate driving transistors can be improved,and the structural problems (structural weak spots) with the electrodeportions can be solved. This eliminates the problem of the decrease inthe reliability or production yield of the display panel.

As seen from above, the present disclosure offers the advantage ofsolving the problem of failure to form capacitors and theirdisappearance due to a short-circuit between electrodes caused bystepped portions on electrode layers, which happens because the designlimit requirements for a layout that requires circuit configurationwithin a limited space of subpixels are tighter in implementing adisplay panel with UHD or higher resolution. Moreover, the presentdisclosure offers the advantage of improving the reliability orproduction yield of the display panel since structural weak spots can beeliminated or avoided by fully covering stepped portions of theelectrode layers within a subpixel so that the capacitors remain.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in embodiments in accordancewith the present disclosure without departing from the spirit or scopeof the invention. Thus, it is intended that the present invention coverthe modifications and variations of this invention provided they comewithin the scope of the appended claims and their equivalents.

What is claimed is:
 1. An organic light-emitting display, comprising: afirst substrate; a semiconductor layer positioned on the firstsubstrate; a first insulating layer positioned on the semiconductorlayer; a gate metal layer positioned on the first insulating layer; asecond insulating layer with a contact hole exposing part of the gatemetal layer; a source-drain metal layer positioned on the secondinsulating layer and electrically connected to the gate metal layer viathe contact hole; a third insulating layer positioned on thesource-drain metal layer; a fourth insulating layer positioned on thethird insulating layer; and a pixel electrode positioned on the fourthinsulating layer; wherein the fourth insulating layer fully covers thecontact hole, and a stepped portion of the pixel electrode caused by thefourth insulating layer is spaced apart from the contact hole.
 2. Theorganic light-emitting display of claim 1, wherein the fourth insulatinglayer is a planarization film which is made of an organic material andmakes flat irregularities beneath the fourth insulating layer.
 3. Theorganic light-emitting display of claim 1, wherein the second insulatinglayer has a first stepped portion on the edge of the gate metal layer,and the fourth insulating layer covers the stepped portion of the secondinsulating layer.
 4. The organic light-emitting display of claim 3,wherein the source-drain metal layer has a second stepped portion alongthe first stepped portion of the second insulating layer, and the fourthinsulating layer covers the second stepped portion of the source-drainmetal layer.
 5. The organic light-emitting display of claim 4, whereinthe third insulating layer has a third stepped portion along the secondstepped portion of the source-drain metal layer, and the fourthinsulating layer covers the third stepped portion of the thirdinsulating layer.
 6. The organic light-emitting display of claim 5,wherein the first stepped portion, the second stepped portion, and thethird stepped portion are disposed adjacent to each other.
 7. Theorganic light-emitting display of claim 1, wherein the gate metal layerin the shape of an island.
 8. The organic light-emitting display ofclaim 1, wherein the fourth insulating layer is shaped in such a manneras to enclose the surrounding area of the contact hole.
 9. The organiclight-emitting display of claim 8, wherein the fourth insulating layerhas a shape in which a part protrudes from an area adjacent to thecontact hole.
 10. The organic light-emitting display of claim 1, whereinthe gate metal layer comprises a horizontal portion and a verticalportion, and the horizontal portion and the vertical portion areconnected together.
 11. The organic light-emitting display of claim 10,wherein the horizontal portion is parallel to the side surface of thefourth insulating layer adjacent to the horizontal portion.